Drive Pinion Shaft Assembly: Installation

Remove the front differential assembly.
Hypoid gear set match mark/No: The number (A) on top of the drive pinion, and the number on the hypoid driven gear are set numbers for the two gears. Use a pair having the same numbers.
The figure (B) below shows a number for shim adjustment. If no number is shown, the value is zero.

Fig 1: Removing Front Differential Assembly
Courtesy of SUBARU OF AMERICA, INC.
Place the drive pinion shaft assembly on transmission main case RH without shim and tighten the bearing mounting bolts.
Check and adjust the ST.
NOTE:
- Loosen the two bolts and adjust so that the scale indicates 0.5 correctly when the plate end and the scale end are on the same level.
- Tighten the two bolts.
ST 499917500 DRIVE PINION GAUGE ASSY

Fig 2: Identifying Drive Pinion Gauge Assy (ST 499917500)
Courtesy of SUBARU OF AMERICA, INC.
Position the ST by inserting the knock pin of ST into the knock hole of transmission case.
ST 499917500 DRIVE PINION GAUGE ASSY
Slide the drive pinion gauge scale with finger tip and read the value at the point where it matches with the end face of drive pinion.
ST 499917500 DRIVE PINION GAUGE ASSY

Fig 3: Sliding Drive Pinion Gauge Scale With Finger Tip
Courtesy of SUBARU OF AMERICA, INC.
The thickness of shim shall be determined by adding the value indicated on drive pinion to the value indicated on the ST. (Add if the number on drive pinion is prefixed by +, and subtract if the number is prefixed by -.)
ST 499917500 DRIVE PINION GAUGE ASSY

Select one to three shims in the following table for the value determined as described above, and take the shim(s) which thickness is closest to the said value.

NOTE: Install the shim with it's cut in facing the shifter fork & rod side.

Drive pinion shim
Part No.	Thickness mm (in)
32295AA031	0.150 (0.0059)
32295AA041	0.175 (0.0069)
32295AA051	0.200 (0.0079)
32295AA061	0.225 (0.0089)
32295AA071	0.250 (0.0098)
32295AA081	0.275 (0.0108)
32295AA091	0.300 (0.0118)
32295AA101	0.500 (0.0197)

Install the front differential assembly. Refer to Front Differential Assembly .
Set the transmission main shaft assembly for single-range and drive pinion shaft assembly in position, and check the shifter fork. Refer to Shifter Fork and Rod .
Install the transmission case. Refer to Transmission Case .
Install the transfer case together with the extension case assembly. Refer to Transfer Case and Extension Case Assembly .
Install the manual transmission assembly to the vehicle. Refer to Manual Transmission Assembly .